Operating Instructions Yamaha Xt660x

Transcript

You can read the recommendations in the user guide, the technical guide or the installation guide for YAMAHA XT660X. You'll find the answers to all your questions on the YAMAHA XT660X in the user manual (information, specifications, safety advice, size, accessories, etc.). Detailed instructions for use are in the User's Guide. User manual YAMAHA XT660X User guide YAMAHA XT660X Operating instructions YAMAHA XT660X Instructions for use YAMAHA XT660X Instruction manual YAMAHA XT660X You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 Manual abstract: Yamaha is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. _ EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. @@@@@@1 The manual is divided into chapters. @@Refer to "SYMBOLS". 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS". 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially. 1 2 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting GEN INFO 3 SPEC 4 CHK ADJ 5 CHAS 6 ENG 7 COOL 8 + FI 9 ELEC 0 Symbols 0 to G indicate the following. 0 Serviceable with engine mounted A Filling fluid B Lubricant C Special tool D Tightening torque E Wear limit, clearance F Engine speed G Electrical data TRBL SHTG A B C D T. R. E F G H I J Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points. M H Engine oil I Gear oil J Molybdenum-disulfide oil K Wheel-bearing grease L Lithium-soap-based grease M Molybdenum-disulfide grease E K B G L LS M M N O Symbols N to O in the exploded diagrams indicate the following. LT New N Apply locking agent (LOCTITE) O Replace the part EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 2 3 4 5 6 7 + SPEC CHK ADJ CHAS ENG COOL FI ELEC 8 9 TRBL SHTG GEN INFO 1 GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION...... .......... ..... ..... .......... .......... ..... ..... .......... 1-1 VEHICLE IDENTIFICATION NUMBER .......... ..... ..... .......... .......... ..... ..... ...1-1 MODEL LABEL....... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... ... 1-1 FEATURES....... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... ..... 1-2 OUTLINE ..... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... ....1-2 FI SYSTEM. ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... 1-3 IMPORTANT INFORMATION .......... .......... ..... ..... .......... .......... ..... ..... .......... ... 1-4 PREPARATION FOR REMOVAL AND DISASSEMBLY....... ..... ..... .......... 1-4 REPLACEMENT PARTS.......... ..... ..... .......... .......... ..... ..... .......... .......... ..... 1-4 GASKETS, OIL SEALS AND O-RINGS ..... .......... .......... ..... ..... .......... ....... 1-4 LOCK WASHERS/PLATES AND COTTER PINS ... ..... ..... .......... .......... .... 1-5 BEARINGS AND OIL SEALS . ..... .......... .......... ..... ..... .......... .......... ..... ..... .. 1-5 CIRCLIPS ........ .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... 1-5 CHECKING THE CONNECTIONS .......... ..... ..... .......... .......... ..... ..... .......... ......1-6 SPECIAL TOOLS .... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... ........ 1-7 GEN INFO MOTORCYCLE IDENTIFICATION EAS00014 GEN INFO GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. 1-1 FEATURES EAS00019 GEN INFO FEATURES EAS00896 OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for engines to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system in place of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to realize cleaner exhaust gases. 1 2 3 4 5 67 8 9 0 A K J 1 Air cut-off valve 2 Air induction system solenoid 3 Engine trouble warning light 4 Fuel tank 5 Fuel pump 6 Fuel hose I H G F E D C B 7 Fuel injector 8 Throttle position sensor 9 Intake air temperature sensor 0 Air filter case A Fuel injection system relay B Battery C Catalytic converter D ECU E Lean angle cut-off switch F Fast idle unit G Crankshaft position sensor H Coolant temperature sensor I Spark plug J Intake air pressure sensor K Ignition coil 1-2 FEATURES EAS00897 GEN INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm2, 46.1 psi) higher than the intake manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the injector is energized (injection duration), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, and coolant temperature sensor enable the ECU to determine the injection duration. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 The injection timing is determined through the signal from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. Illustration is for reference only. #1 2 1 5 47 6 9 8 0 3 1 Fuel pump 2 Pressure regulator 3 Fuel injector 4 Throttle body 5 Intake air temperature sensor 6 Throttle position sensor 7 Intake air pressure sensor 8 ECU 9 Coolant temperature sensor 0 Crankshaft position sensor Fuel system Air system Control system 1-3 IMPORTANT INFORMATION EAS00020 GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to "SPECIAL TOOLS". 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been "mated" through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS00022 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. 1-4 IMPORTANT INFORMATION EAS00023 GEN INFO LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer's marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal CAUTION: _ Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1 Bearing EAS00025 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4 Shaft 1-5 CHECKING THE CONNECTIONS EAS00026 GEN INFO CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. _ 4. needed to hold the clutch boss when removing or installing the boss nut. Valve lapper 90890-04101 This tool is used for lapping the valve. Adapter 90890-04130 Spacer 90890-04144 Adapter Spacer (crankshaft installer) These tools are used to install the crankshaft. Ignition checker 90890-06754 This tool is used to check the ignition system components. 1 - 10 SPECIAL TOOLS Tool No. Tool name/Function Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating surfaces (e.g. , crankcase mating surfaces). GEN INFO Illustration 1 - 11 SPEC 2 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ......... .......... ..... ..... .......... ..... Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Maximum impeller shaft tilt Starting system type Fuel injector Model/manufacturer Quantity Spark plug Model/manufacturer quantity Spark plug gap Cylinder head Volume Maximum warpage Standard Trochoid 0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in) 0. 03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.03 ~ 0. 08 mm (0.0012 ~ 0.0031 in) SPEC Limit ---0.2 mm (0.008 in) 0. 15 mm (0.0059 in) 0.15 mm (0.0059 in) ------- 1.00 L (0.88 Imp, 1.06 US qt) 110.0 ~ 140.0 kPa (1.10 ~ 1. 40 kg/cm2, 16.0 ~ 20.3 psi) 280.0 mm (11.02 in) 158.0 mm (6.22 in) 23.0 mm (0.91 in) 0.25 L (0. 22 Imp, 0.26 US qt) 0.15 L (0.13 Imp, 0.16 US qt) Single-suction centrifugal pump 27/28 (0. 964) ---Electric starter 297500-0390/DENSO 1 CR7E/NGK 1 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 59. 10 ~ 60.50 cm3 (3.61 ~ 3.69 cu in) ---- ---------------------0.15 mm (0.006 in) ------------------0.03 mm (0.0012 in) 2-3 ENGINE SPECIFICATIONS Item Camshaft Drive system Intake camshaft lobe dimensions Standard Chain drive (left) SPEC Limit ---- A B Measurement A Measurement B Exhaust camshaft lobe dimensions 43.488 ~ 43.588 mm (1. 7121 ~ 1.7161 in) 43.338 mm (1.7062 in) 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm (1.4504 in) A B Measurement A Measurement B Valve timing Intake - open (B. T.D.C.) Intake - closed (A.B. D.C.) Exhaust - open (B.B.D. C.) Exhaust - closed (A.T.D.C.) Overlap angle "A" Maximum camshaft runout 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 42. 983 mm (1.6922 in) 37.007 ~ 37.107 mm (1.4570 ~ 1.4609 in) 36.886 mm (1.4522 in) 25 55 60 20 45 ------------------0.040 mm (0.0016 in) Timing chain Model/number of links Tensioning system 98 RH2010/126 Automatic ------- 2-4 ENGINE SPECIFICATIONS Item Rocker arm/rocker arm shaft Rocker arm inside diameter Shaft outside diameter Arm-to-shaft clearance Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Standard SPEC Limit 12. 000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm (0. 4739 in) 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11. 955 mm (0.4707 in) 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.081 mm (0.0032 in) 0.09 ~ 0.13 mm (0. 0035 ~ 0.0051 in) 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ------- B A C D Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust 37.90 ~ 38.10 mm (1.4921 ~ 1.5000 in) 31. 90 ~ 32.10 mm (1.2559 ~ 1.2638 in) 2.260 mm (0. 0890 in) 1.91 ~ 2.62 mm (0.075 ~ 0.103 in) 1. 00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) ------------1.6 mm (0.06 in) 1. 6 mm (0.06 in) ------5.945 mm (0.2341 in) 5.930 mm (0.2335 in) 6.05 mm (0.2382 in) 6.05 mm (0.2382 in) 0. 80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 0.80 ~ 1. 20 mm (0.0315 ~ 0.0472 in) 5.975 ~ 5.990 mm (0. 2352 ~ 0.2358 in) 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6. 000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 2-5 ENGINE SPECIFICATIONS Item Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout Standard SPEC Limit 0. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 08 mm (0.0031 in) 0.10 mm (0.0039 in) 0.010 mm (0.0004 in) 0. 010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.025 ~ 0. 052 mm (0.0010 ~ 0.0020 in) ---- Valve seat width Intake Exhaust Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt 1.00 ~ 1.20 mm (0. 0394 ~ 0.0472 in) 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.06 in) 1.6 mm (0.06 in) 40. 38 mm (1.59 in) 40.38 mm (1.59 in) 38.36 mm (1.51 in) 38.36 mm (1.51 in) ------------- 35.00 mm (1.38 in) 35. 00 mm (1.38 in) 171 ~ 197 N (17.44 ~ 20.09 kg, 38.44 ~ 44. 29 lb) 171 ~ 197 N (17.44 ~ 20.09 kg, 38.44 ~ 44.29 lb) Intake Exhaust Winding direction (top view) Intake Exhaust ------- 2. 5/1.8 mm (2.5/0.071 in) 2.5/1.8 mm (2.5/0.071 in) Clockwise Clockwise ------- 2-6 ENGINE SPECIFICATIONS Item Cylinder Cylinder arrangement Bore stroke Compression ratio Bore Maximum taper Maximum out-of-round Piston Piston-to-cylinder clearance Diameter D Standard SPEC Limit ---------100.080 mm (3.9402 in) 0. 05 mm (0.002 in) 0.05 mm (0.002 in) Forward-inclined single cylinder 100.0 84.0 mm (3.94 3.31 in) 10 : 1 100.000 ~ 100.010 (3. 9370 ~ 3.9374 in) ------- 0.13 mm (0.0051 in) 99.955 ~ 99. 970 mm (3.9352 ~ 3.9358 in) ---- 0.030 ~ 0.055 mm (0. 0012 ~ 0.0022 in) H D Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pin Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring B T 10.0 mm (0.39 in) ---- 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm (0.9073 in) 0. 50 mm (0.0197 in) ---Intake side ---22.991 ~ 23.000 (0.9052 ~ 0.9055 in) 0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) 22. 971 mm (0.9044 in) 0.074 mm (0.0029 in) Ring type Dimensions (B T) End gap (installed) Ring side clearance Barrel 1.20 3. 80 mm (0.047 0.150 in) 0.20 ~ 0.35 mm (0. 0079 ~ 0.0138 in) 0.030 ~ 0.080 mm (0.0012 ~ 0.0031 in) ------0.60 mm (0.0236 in) 0.13 mm (0.0051 in) 2-7 ENGINE SPECIFICATIONS Item 2nd ring B T SPEC Limit Standard Ring type Dimensions (B T) End gap (installed) Ring side clearance Oil ring B T Taper 1. 20 4.00 mm (0.047 0.157 in) 0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in) 0.030 ~ 0.070 mm (0. 0012 ~ 0.0028 in) ------0.85 mm (0.0335 in) 0.11 mm (0. 0043 in) Dimensions (B T) End gap (installed) Ring side clearance Crankshaft F C C 2.50 3.40 mm (0.098 0.134 in) 0. 20 ~ 0.70 mm (0.0079 ~ 0.0276 in) 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---------- E D A Width A Maximum runout C Big end side clearance D Big end radial clearance E Small end free play F Balancer Balancer drive method 74.95 ~ 75.00 mm (2. 9508 ~ 2.9528 in) ---0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in) 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) 0. 16 ~ 0.40 (0.0063 ~ 0.0157 in) Gear ---0.04 mm (0. 0016 in) 1.0 mm (0.04 in) ---------- 2-8 ENGINE SPECIFICATIONS Item Clutch Clutch type Clutch release method Operation Clutch cable free play (at the end of the clutch lever) Friction plates 1 (inside dia.: 120 mm) Thickness Plate quantity Friction plates 2 Thickness Plate quantity Friction plates 3 (inside dia.: 128 mm) Thickness Plate quantity Clutch plates Thickness Plate quantity Maximum warpage Clutch spring Free length Spring quantity Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear Standard Wet, multiple disc Outer pull, rack and pinion pull Left-hand operation 10. 0 ~ 15.0 mm (0.39 ~ 0.59 in) SPEC Limit ------------- 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) 4 2.92 ~ 3.08 mm (0. 115 ~ 0.121 in) 2 2.80 mm (0.110 in) ---2.80 mm (0.110 in) ---- 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) 1 1. 50 ~ 1.70 mm (0.059 ~ 0.067 in) 6 ---- 2.80 mm (0. 110 in) ---------0.20 mm (0.0079 in) 52.82 mm (2.08 in) ------------------------------------- 55. 6 mm (2.19 in) 5 Constant mesh, 5-speed Spur gear 75/36 (2.083) Chain drive 45/15 (3.000) Left-foot operation 30/12 (2.500) 26/16 (1.625) 23/20 (1.150) 20/22 (0.909) 20/26 (0.769) 2-9 ENGINE SPECIFICATIONS Item Maximum main axle runout Maximum drive axle runout Shifting mechanism Shift mechanism type Decompression device Device type Air filter type Fuel pump Pump type Model/manufacturer Consumption amperage Output pressure Throttle body Model/manufacturer quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID mark Throttle valve size ------Standard SPEC Limit 0.08 mm (0. 0031 in) 0.08 mm (0.0031 in) ------------------------------------- Shift drum and guide bar Auto decomp Oil-coated paper element Electrical 5VK/DENSO 3.5 A 294 kPa (2.94 kg/cm2, 41.8 psi) 44EHS/MIKUNI 1 37.6 ~ 40.2 kPa (282 ~ 302 mmHg, 11.1 ~ 11.9 inHg) 3. 0 ~ 5.0 mm (0.12 in ~ 0.20 mm) 5VK1 00 #50 2 - 10 CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Wheel axle bending limit Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Wheel axle bending limit Standard Diamond 27.25 (XT660R) 26 (XT660X) 107 mm (4. 21 in) (XT660R) 94 mm (3.70 in) (XT660X) Spoke wheel 21 1.85 (XT660R) 17M/C MT3.50 (XT660X) Aluminum 225 mm (8.86 in) (XT660R) 200 mm (7. 87 in) (XT660X) ---------- SPEC Limit ---------------------------------2.0 mm (0.08 in) 2.0 mm (0.08 in) 0.25 mm (0.01 in) ---------------2.0 mm (0.08 in) 2.0 mm (0. 08 in) 0.25 mm (0.01 in) Spoke wheel 17M/C MT2.75 (XT660R) 17M/C MT4.25 (XT660X) Aluminum 200.0 mm (7.87 in) ---------- 2 - 11 CHASSIS SPECIFICATIONS Item Front tire Tire type Size Standard With tube 90/90-21M/C 54S, 90/90-21M/C 54T (XT660R) 120/70R 17M/C 58 H (XT660X) TOURANCE FRONT/METZELER, SIRAC/MICHELIN (XT660R) DRAGON/PIRELLI (XT660X) SPEC Limit ---------------- Model/manufacturer Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 (198 lb) ~ Maximum load* Off-road riding Minimum tire tread depth Rear tire Tire type Size 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) 210 kPa (2.10 kgf/cm, 30 psi) (XT660X) 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) 220 kPa (2. 20 kgf/cm, 31 psi) (XT660X) * Load is the total weight of the cargo, rider, passenger and accessories. 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) ---- ---------------1.6 mm (0.063 in) ---------------------------- Model/manufacturer With tube 130/80-17M/C 65S, 130/80-17M/C 65T (XT660R) 160/60R 17M/C 69H (XT660X) TOURANCE/METZELER, SIRAC A/ MICHELIN (XT660R) DRAGON/PIRELLI (XT660X) 200 kPa (2. 00 kgf/cm, 29 psi) (XT660R) 210 kPa (2.10 kgf/cm, 30 psi) (XT660X) 225 kPa (2.25 kgf/cm, 33 psi) (XT660R) 230 kPa (2.30 kgf/cm, 33 psi) (XT660X) * Load is the total weight of the cargo, rider, passenger and accessories. 200 kPa (2. 00 kgf/cm, 29 psi) (XT660R) ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 (198 lb) ~ Maximum load* Off-road riding Minimum tire tread depth ---1.6 mm (0.063 in) 2 - 12 CHASSIS SPECIFICATIONS Item Front brakes Brake type Operation Recommended fluid Brake discs Diameter thickness Standard Singledisc brake Right-hand operation DOT 4 298. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 0 4.5 mm (11.73 0.18 in) (XT660R) 320.0 4.5 mm (12.60 0. 18 in) (XT660X) ------inner 4.1 mm (0.16 in) (XT660R) 5.2 mm (0.20 in) (XT660X) Pad thickness outer 4.1 mm (0.16 in) (XT660R) 5.2 mm (0.20 in) (XT660X) Master cylinder inside diameter Caliper cylinder inside diameter 12.7 mm (0. 50 in) 32.00 mm 1 (1.26 in 1) and 30.00 mm 1 (1.18 in 1) (XT660R) 34. 00 mm 2 (1.34 in 2) and 30.00 mm 2 (1.18 in 2) (XT660X) Single-disc brake Right-foot operation 12.0 mm (0. 47 in) DOT 4 245 5.0 mm (9.65 0.20 in) ------inner outer 5.5 mm (0.22 in) 5.5 mm (0.22 in) 12.7 mm (0.50 in) 34. 00 mm 1 (1.34 in 1) SPEC Limit ---------------4.0 mm (0.16 in) 0.15 mm (0.006 in) 1.0 mm (0.04 in) 1.0 mm (0.04 in) 1. 0 mm (0.04 in) 1.0 mm (0.04 in) ---------- Minimum thickness Maximum deflection Pad thickness Rear brake Brake type Operation Brake pedal position (below the top of the rider footrest) Recommended fluid Brake discs Diameter thickness Minimum thickness Maximum deflection Pad thickness Pad thickness ---------------4.5 mm (0. 18 in) 0.15 mm (0.006 in) 1.0 mm (0.04 in) 1. 0 mm (0.04 in) ------- Master cylinder inside diameter Caliper cylinder inside diameter 2 - 13 CHASSIS SPECIFICATIONS Item Steering Steering bearing type Lock to lock angle (left) Lock to lock angle (right) Front suspension Suspension type Front fork type Front fork travel Spring Free length Standard Taper roller bearing 44.0 44.0 Telescopic fork Coil spring/oil damper 225.0 mm (8.86 in) (XT660R) 200.0 mm (7.87 in) (XT660X) 633.0 mm (24.92 in) (XT660R) 593. 0 mm (23.35 in) (XT660X) Spacer length Installed length Spring rate (K1) SPEC Limit ---------------------620 mm (24.41 in) 581 mm (22.87 in) ---------------------------------------------------- Spring stroke (K1) Spring rate (K2) Spring stroke (K2) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) 0 mm (0 in) 628.0 mm (24.72 in) (XT660R) 588.0 mm (23.15 in) (XT660X) 3.75 N/mm (0.38 kg/mm, 21. 41 lb/in) (XT660R) 3.75 N/mm (0.38 kg/mm, 21.41 lb/in) (XT660X) 0 ~ 120.0 mm (0 ~ 4. 72 in) (XT660R) 0 ~ 120.0 mm (0 ~ 4.72 in) (XT660X) 6.00 N/mm (0.61 kg/mm, 34. 26 lb/in) (XT660R) 6.00 N/mm (0.61 kg/mm, 34.26 lb/in) (XT660X) 120.0 ~ 225.0 mm (4.72 ~ 8.86 in) (XT660R) 120.0 ~ 200.0 mm (4. 72 ~ 7.87 in) (XT660X) No Fork oil 10 W or equivalent 640.0 cm3 (22.53 Imp oz, 21.64 US oz) (XT660R) 600.0 cm3 (21.12 Imp oz, 20.29 US oz) (XT660X) 125.0 mm (4.92 in) (XT660R) 125. 0 mm (4.92 in) (XT660X) Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) Inner tube outer diameter Inner tube bearing 43.0 mm (1.69 in) ---- ---0.2 mm (0. 0079 in) 2 - 14 CHASSIS SPECIFICATIONS Item Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Standard Swingarm (monocross) Coil spring/gas-oil damper 65.0 mm (2.56 in) 216.0 mm (8.50 in) SPEC Limit ---------- 205 mm (8. 07 in) Installed length 206.0 mm (8.11 in) ---Spring rate (K1) 125.00 N/mm (12.75 kg/mm, 713.75 lb/in) ---Spring stroke (K1) 0 ~ 65.0 mm (0 ~ 2.56 in) ---Optional spring available No ---2 Standard spring preload gas/air pres- 980 kPa (9.8 kg/cm , 139.4 psi) ---sure Swingarm Free play (at the end of the swingarm) Radial ---1. 0 mm (0.04 in) Axial ---1.0 mm (0.04 in) Drive chain Type/manufacturer DID520VP/DAIDO ---Link quantity 110 ---Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) ---Maximum 15-link section 240.5 mm (9.47 in) ---- 2 - 15 ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing Advancer type Crankshaft position senor resistance/ color Transistorized coil ignition unit model/manufacturer Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance Charging system System type Model/manufacturer Nominal output Stator coil resistance/color Rectifier/regulator Regulator type Model/manufacturer No-load regulated voltage Rectifier capacity Withstand voltage Battery Battery type/manufacturer Battery voltage/capacity Ten hour rate amperage Headlight type Indicator light (voltage/wattage quantity) Neutral indicator light High beam indicator light Fuel level warning light Turn signal indicator light Engine trouble warning light Coolant temperature warning light Immobilizer system indicator light 12 V Transistorized coil ignition (digital) 9. 0 BTDC at 1,400 r/min Electric 192 ~ 288 at 20 C (68 F) blue/yellowgreen/white TBDF08/DENSO Standard SPEC Limit ------------------- JO300/DENSO 6.0 mm (0.24 in) 3.4 ~ 4.6 at 20 C (68 F) 10. 4 ~ 15.6 k at 20 C (68 F) Rubber 10.0 k at 20 C (68 F) A.C. magneto LMX51/DENSO 14. 0 V/20.8 A at 5,000 r/min 0.224 ~ 0.336 at 20 C (68 F) whitewhite Semiconductor, short circuit SH713AA/SHINDENGEN 14.1 ~ 14.9 V 35.0 A 200.0 V GT9B-4/GS 12 V/8.0 AH 0.8 A Halogen bulb ------------------------------- ---------------------------- LED 1 LED 1 LED 1 LED 1 LED 1 LED 1 LED 1 ---------------------- 2 - 16 ELECTRICAL SPECIFICATIONS Item Bulbs (voltage/wattage quantity) Headlight Auxiliary light Tail/brake light Front turn signal light Rear turn signal light Meter lighting Electric starting system System type Starter motor Model/manufacturer Power output Armature coil resistance Brushes Overall length Spring force Commutator diameter Mica undercut Starter relay Model /manufacturer Amperage Coil resistance Horn Horn type Model/manufacturer quantity Maximum amperage Performance Coil resistance Turn signal/hazard relay Relay type Model/manufacturer Self-cancelling device built-in Turn signal blinking frequency Wattage Relay unit Model/manufacturer Coil resistance Diode Throttle position sensor Model/manufacturer Resistance Standard 12 V 55. 0 W/60.0 W 1 12 V 5.0 W 1 12 V 5.0 W/21.0 W 1 12 V 10.0 W 2 12 V 10.0 W 2 EL Constant mesh SM-13/MITSUBA 0.80 kW 0.025 ~ 0.035 at 20 C (68 F) 12. 5 mm (0.49 in) 7.65 ~ 10.01 N (780 ~ 1,021 gf, 27.51 ~ 36. 01 oz) 28.0 mm (1.10 in) 0.70 mm (0.028 in) MS5F-561/JIDECO 180. 0 A 4.18 ~ 4.62 at 20 C (68 F) Plane YF-12/NIKKO 1 3.0 A 105 ~ 120 db/2 m (6.6 ft) 1.15 ~ 1.25 at 20 C (68 F) Full-transistor FE218BH /DENSO No 75 ~ 95 cycles/min. 10 W 2 + 3.4 W G8R-30Y-V4/OMRON 162 ~ 198 Yes 5PS1/MIKUNI 4.0 ~ 6. 0 k SPEC Limit ------------------------------5.00 mm (0.20 in) ---27 mm (1.06 in) ---------------------------------------------------------- 2 - 17 ELECTRICAL SPECIFICATIONS Item Headlight relay Model/manufacturer Radiator fan Model/manufacturer Fan motor relay Model/manufacturer Intake air pressure sensor Thermostat type/manufacturer Output voltage Intake air temperature sensor Model/manufacturer Resistance Coolant temperature sensor Model/manufacturer Resistance Standard ACM33211 M04/MATSUSHITA 5VW/KTM ACM33211 M04/MATSUSHITA 5PS1/DENSO 3.4 ~ 3.8 V 5VU1/DENSO 2.21 ~ 2.69 k at 20 C (68 F) 0.290 ~ 0.354 k at 80 C (176 F) 5PS1/DENSO 2. 32 ~ 2.59 k at 20 C (68 F) 0.310 ~ 0.326 k at 80 C (176 F) 0.140 ~ 0. 145 k at 110 C (230 F) 30 A 1 10 A 1 20 A 1 10 A 1 10 A 1 7.5 A 1 10 A 1 10 A 1 30 A 1 20 A 1 10 A 1 7. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 5 A 1 SPEC Limit ------------------------------------------------------------------------- Fuses (amperage quantity) Main fuse Signaling system fuse Headlight fuse Ignition fuse Fuel injection system fuse Radiator fan motor fuse Parking lighting fuse Backup fuse (immobilizer unit, meter assembly) Reserve fuse 2 - 18 CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 SPEC CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC ** mm 2 mm MULTIPLIER 0.03937 0.03937 = = IMPERIAL ** in 0.08 in GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. CONVERSION TABLE METRIC TO IMPERIAL Metric unit m kg Tightening torque m kg cm kg cm kg Weight Speed kg g km/hr km m m cm mm cc (cm3) cc (cm3) lt (liter) lt (liter) kg/mm kg/cm2 Centigrade (C) Multiplier 7.233 86. 794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0. 03937 0.03527 0.06102 0.8799 0.2199 55. 997 14.2234 9/5+32 Imperial unit ft lb in lb ft lb in lb lb oz mph mi ft yd in in oz (IMP liq.) cu in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in2) Fahrenheit (F) Distance A: Distance between flats B: Outside thread diameter A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General tightening torques Nm 6 15 30 55 85 130 m kg 0. 6 1.5 3.0 5.5 8.5 13.0 ft lb 4.3 11 22 40 61 94 Volume/ Capacity Misc. 2 - 19 TIGHTENING TORQUE TIGHTENING TORQUE ENGINE TIGHTENING TORQUE Part to be tightened Cylinder head (exhaust pipe) Cylinder head (left side) = 145 mm (5.71 in) Cylinder head (right side) = 135 mm (5.31 in) Cylinder head (center lower side) Cylinder head Spark plug Cylinder (left side) = 116 mm (4. 57 in) 1st 2nd Cylinder (right side) = 109 mm (4.29 in) 1st 2nd Cylinder Tappet cover (exhaust side) Tappet cover (intake side) Camshaft sprocket cover Camshaft sprocket Camshaft retainer Valve adjusting screw Balancer driven gear Part name Stud bolt Bolt Bolt Bolt Bolt -- Bolt Thread Q'ty size M8 M9 M9 M9 M6 M10S M10 4 2 2 2 2 1 2 SPEC Tightening torque Nm m kg ft lb 15 50 50 45 10 13 15 50 1.5 5.0 5.0 4.5 1.0 1.3 1.5 5.0 1. 5 5.0 1.0 1.0 1.0 1. 0 2.0 1.0 1.4 7.0 11 36 36 32 7. 2 9.4 11 36 11 36 7.2 7.2 7.2 7.2 14 7.2 10 50 Remarks E E E E Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut M10 M6 M6 M6 M6 M7 M6 M6 M18 2 2 4 4 2 2 2 4 1 15 50 10 10 10 10 20 10 14 70 E LT Use a lock washer. E Primary drive gear Timing chain tensioner Timing chain tensioner cap Timing chain guide (intake) Thermostat cover Coolant temperature sensor Water pump cover Water pump assembly Water pump outlet pipe Water jacket joint Crankcase cover (right) Nut Bolt Bolt Bolt Bolt -- Bolt Bolt Bolt Bolt Bolt M20 M6 M16 M6 M6 M12 M6 M6 M6 M6 M6 1 2 1 2 2 1 3 2 1 2 9 80 10 20 8 10 18 10 10 10 10 10 8.0 1.0 2. 0 0.8 1.0 1.8 1.0 1.0 1.0 1.0 1.0 58 7.2 14 5. 8 7.2 13 7.2 7.2 7.2 7. 2 7.2 Use the lock washer. M 2 - 20 TIGHTENING TORQUE Part to be tightened Oil strainer Oil pump Oil baffle plate 2 Oil pump assembly Engine oil drain bolt (crankcase) Oil filter element cover Oil filter drain bolt Engine oil drain bolt (oil tank) Bleed bolt (oil filter element) Oil delivery pipe 1 Oil delivery pipe 2 Oil delivery hose 1 Oil delivery hose 2 Throttle body joint clamp screw Air filter case joint clamp screw Air filter case Exhaust pipe and exhaust pipe bracket Exhaust pipe bracket and frame Exhaust pipe and muffler Exhaust pipe Muffler Exhaust pipe and muffler Air cut-off valve outlet pipe Clutch cover Clutch cable holder Clutch spring Clutch boss Shift shaft spring stopper Torque limiter cover A.C. magneto cover A. C. magneto rotor A.C. magneto lead holder Crankcase (left side) Crankcase (right side) Lead holder Bearing retainer Part name Bolt Screw Bolt Screw Bolt Bolt Bolt Bolt Bolt Union Bolt Bolt Union Bolt Bolt Bolt -- -- Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Thread Q'ty size M6 M6 M5 M6 M14 M6 M6 M8 M5 M10 M6 M8 M6 M6 M4 M5 M6 M8 M8 M8 M8 M8 M8 M6 M6 M6 M6 M20 M8 M6 M6 M16 M6 M6 M6 M6 M6 3 3 2 1 1 2 1 1 1 2 1 2 1 2 2 1 4 2 2 1 4 4 2 2 7 2 5 1 1 4 8 1 1 6 8 2 3 SPEC Remarks LT Tightening torque Nm m kg ft lb 10 10 4 7 30 10 10 18 5 20 10 18 10 10 6 4 10 27 23 12 20 27 20 10 10 10 9 90 22 10 10 80 10 10 10 10 10 1.0 1.0 0.4 0.7 3.0 1.0 1. 0 1.8 0.5 2.0 1.0 1.8 1.0 1.0 0.6 0.4 1. 0 2.7 2.3 1.2 2.0 2. 7 2.0 1.0 1.0 1.0 0. 9 9.0 2.2 1.0 1.0 8.0 1.0 1.0 1.0 1.0 1. 0 7.2 7.2 2.9 5.1 22 7.2 7.2 13 3.6 14 7.2 13 7.2 7. 2 4.3 2.9 7.2 19 17 8.7 14 19 14 7. 2 7.2 7.2 6.5 65 16 7.2 7. 2 58 7.2 7.2 7.2 7.2 7.2 LT LT Sealant LT E E LT E LT LT 2 - 21 TIGHTENING TORQUE Part to be tightened Starter clutch Stator coil Crankshaft position sensor Starter motor and crankcase Starter motor lead Brush holder and starter motor yoke Starter motor assembly Drive axle oil seal retainer Drive sprocket Neutral switch Speed sensor Shift pedal Intake air pressure sensor Cylinder head tightening sequence: Part name Bolt Bolt Bolt Bolt Nut Nut Bolt Nut Nut Bolt Bolt Bolt Nut Thread Q'ty size M8 M6 M5 M6 M6 M6 M5 M6 M18 M6 M6 M6 M6 3 3 2 2 1 1 2 2 1 2 1 1 2 SPEC Remarks LT LT LT Tightening torque Nm m kg ft lb 30 10 7 10 5 11 5 10 120 4 10 16 7 3.0 1.0 0.7 1.0 0. 5 1.1 0.5 1.0 12.0 0.4 1.0 1.6 0.7 22 7.2 5. 1 7.2 3.6 8 3.6 7.2 85 2. 9 7.2 11 5.1 Sealant Use the lock washer. LT 2 3 1 4 2 - 22 TIGHTENING TORQUE CHASSIS TIGHTENING TORQUES Part to be tightened Engine mounting: Engine upper bracket and frame Engine upper bracket and engine Engine front bracket and frame Engine front bracket and engine Engine and frame Radiator cap retainer Coolant reservoir Chain tensioner (upper and lower) Pivot shaft and nut Rear shock absorber and frame Relay arm and frame Relay arm and connecting arm Swingarm and connecting arm Relay arm and rear shock absorber Chain cover and swingarm Stabilizer (XT660X) Chain protector and swingarm Drive sprocket cover Upper bracket pinch bolt Lower handlebar holder and upper bracket Steering stem nut Lower ring nut (steering stem) Upper handlebar holder and lower handlebar holder Front brake master cylinder holder Clutch lever holder Front brake master cylinder and brake lever Grip end Front brake hose union bolt Front mud guard (XT660R) Front mud guard and front fork protector (XT660R) Stabilizer and front mud guard (XT660X) Stabilizer, front mud guard, and front fork (XT660R) Front brake hose holder and front fork Upper bracket pinch bolt Lower bracket pinch bolt Cap bolt Damper rod bolt Thread size M10 M10 M10 M10 M10 M6 M6 M8 M14 M14 M14 M14 M14 M10 M6 M6 M6 M6 M8 M10 M22 M25 M8 M6 M5 M6 M6 M10 M6 M6 M6 M8 M6 M8 M8 M50 M12 SPEC Tightening torque Nm m kg ft lb 73 55 73 73 73 7 5 23 92 59 59 59 59 42 7 7 7 10 23 32 130 -- 23 7 7 6 7 30 7 7 7 16 10 23 23 18 30 7. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 3 5. 5 7.3 7.3 7.3 0.7 0.5 2.3 9.2 5.9 5.9 5. 9 5.9 4.2 0.7 0.7 0.7 1.0 2.3 3.2 13.0 -- 2. 3 0.7 0.7 0.6 0.7 3. 0 0.7 0.7 0.7 1.6 1. 0 2.3 2.3 1.8 3.0 53 40 53 53 53 5.1 3.6 17 66 43 43 43 43 30 5.1 5.1 5.1 7. 2 17 23 94 -- 17 5.1 5.1 4.3 5.1 22 5.1 5.1 5.1 11 7.2 17 17 13 22 Remarks LS LS LS LS LS See NOTE. LS LT 2 - 23 TIGHTENING TORQUE Part to be tightened Fuel tank and frame Fuel pump and fuel tank Rectifier/regulator and air filter case ECU and air filter case Horn bracket and frame Side panels (left and right) and frame Grab bar, rear cover and frame Rear mud guard and frame Tail/brake light and rear mud guard Rear mud guard and rear fender Rear fender and frame Front fender and frame Front fork protector and front cowling assembly Front brake disc and wheel Front wheel axle Front wheel axle pinch bolt Front brake caliper Brake caliper bleed screw Rear wheel axle nut Chain drive adjusting locknut Rear wheel sprocket and hub Rear brake disc and wheel Left side heel plate Right side heel plate and rear brake master cylinder Brake pedal position locknut Footrest bracket and frame (right) Rear brake hose holder and swingarm Rear brake hose union bolt Rear brake caliper protector (front side) Rear brake caliper protector (rear side) Thread size M6 M5 M6 M6 M6 M6 M8 M6 M6 M6 M6 M6 M6 M8 M16 M8 M10 M10 M16 M8 M10 M6 M6 M8 M8 M10 M6 M10 M6 M6 SPEC Remarks Tightening torque Nm m kg ft lb 10 4 7 7 10 7 23 7 4 7 7 7 8 23 59 18 40 14 105 16 69 13 10 23 18 48 7 30 7 4 1. 0 0.4 0.7 0.7 1.0 0. 7 2.3 0.7 0.4 0.7 0. 7 0.7 0.8 2.3 5.9 1.8 4.0 1.4 10.5 1.6 6. 9 1.3 1.0 2.3 1.8 4.8 0.7 3.0 0.7 0.4 7. 2 2.9 5.1 5.1 7.2 5. 1 17 5.1 2.9 5.1 5.1 5. 1 5.8 17 43 13 29 10 75 11 50 9.4 7.2 17 13 35 5.1 22 5.1 2.9 LT LT NOTE: 1. First, tighten the lower ring nut approximately 43 Nm (4.3 m kg, 31 ft lb) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut 7 Nm (0.7 m kg, 5.1 ft lb) by using the torque wrench. 2 - 24 LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Oil seal lips O-rings Bearings Cylinder head tightening bolts Cylinder tightening bolts Crankshaft pin Timing chain sprocket inner surface Connecting rod big end thrust surface Piston pin Piston and ring groove Balancer weight tightening nut A.C. magnet rotor tightening nut inner surface Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Rocker arm shaft Camshaft lobes Decompressor lever pin Decompressor lever spring Water pump impeller shaft Oil pump rotors (inner and outer) Oil pump shaft Torque limiter Starter clutch idle gear thrust surface Starter clutch idle gear inner surface Starter clutch gear (inner and outer) Starter clutch assembly Primary drive gear tightening nut Primary driven gear Clutch boss tightening nut Push rod Transmission gears (wheel and pinion) Main and drive axle Shift forks Shift drum Shift shaft Shift shaft spacer M M Symbol LS LS E E E E M E E E E E M M E M E E E E E E E E E E M E E M E E E E 2 - 25 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Crankcase mating surface A.C. magnet lead grommet (A.C. magneto cover) Oil seal holder tightening bolt Oil delivery hose 2 tightening bolt SPEC Symbol Yamaha bond No. 1215 Yamaha bond No.1215 Yamaha bond No.1215 Yamaha bond No.1215 2 - 26 LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 SPEC CHASSIS Lubrication Point Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right) Rear wheel drive hub contact surface Rear arm pivot shaft outer surface and bush outer surface and oil seal lip Dust cover thrust surface Relay arm and rear shock absorber mounting bolt outer surface Relay arm and rear shock absorber oil seal lips Relay arm and swingarm mounting bolt outer surface Relay arm and swingarm oil seal lips Relay arm and connecting arm mounting bolt outer surface Relay arm and connecting arm oil seal lips Brake pedal outer surface Rear brake master cylinder pin outer surface Steering head pipe bearings (upper and lower) Steering head pipe bearing races (upper and lower) Tube guide (throttle grip) inner surface Clutch lever pivot bolt outer surface Sidestand sliding surface and collar outer surface Footrest pivoting point Footrest spring end Chain tensioner collar (upper and lower) outer surface Rear axle shaft outer surface Passenger footrest pivoting point Symbol LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS 2 - 27 COOLING SYSTEM DIAGRAMS EAS00033 SPEC COOLING SYSTEM DIAGRAMS 1 Water jacket joint 2 Water pump outlet hose 3 Water pump outlet pipe 4 Water pump From the radiator To the cylinder 1 2 A 3 2 5VK00 1 5VK 3 A 4 4 2 - 28 COOLING SYSTEM DIAGRAMS 1 Fast idle plunger outlet hose 2 Coolant reservoir breather hose 3 Coolant reservoir hose 4 Radiator cap 5 Radiator 6 Coolant reservoir cap 7 Coolant reservoir 8 Radiator outlet hose 9 Water pump 0 Radiator fan A Radiator inlet hose From the fast idle plunger To the cylinder From the thermostat SPEC 1 23 4 5 6 7 8 5 A 9 0 2 29 LUBRICATION CHART LUBRICATION CHART SPEC : Pressure feed : Splashed scavenge Camshaft Cylinder head Oil tank Drive axle Oil filter Crankshaft Main axle Check ball Connecting rod Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan 2 - 30 LUBRICATION DIAGRAMS EAS00034 SPEC LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 1 A-A 2 A A 3 2 2 - 31 LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump SPEC 3 A-A 1 2 A 3 A 4 2 - 32 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 To oil tank SPEC 2 3 1 7 6 5 4 2 - 33 LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft SPEC 2 1 6 3 5 4 2 - 34 CABLE ROUTING EAS00035 SPEC CABLE ROUTING 1 Left handlebar switch lead 2 Clutch switch lead 3 Clutch cable 4 Front brake light switch lead 5 Right handlebar switch lead 6 Throttle cable 7 Headlight lead 8 Meter assembly lead 9 Main switch lead 0 Immobilizer unit lead 2 - 35 CABLE ROUTING When fastening the front brake light switch lead, leave some slack in the lead at the area shown. Fasten the right handlebar switch lead, front brake light switch lead, and throttle cables with a plastic band. Face the end of the plastic band forward. Fasten the clutch cable with a cable holder. Fasten the left handlebar switch lead and clutch switch lead with a plastic band. Face the end of the plastic band forward. SPEC Route the throttle cables, left handlebar switch lead, right handlebar switch lead, front brake light switch lead, and clutch switch lead in front of the steering column, then the clutch cable, then the headlight lead and meter assembly lead, and finally the main switch lead and immobilizer unit lead. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 2 - 36 CABLE ROUTING 1 Front turn signal light lead (right) 2 Meter assembly lead 3 Auxiliary light lead 4 Front turn signal light lead (left) 5 Headlight lead 6 Sub-wire harness SPEC Fasten the sub-wire harness and meter assembly lead with a plastic band. Fasten the sub-wire harness at the white tape. Face the end of the plastic band forward. Make sure that there is no slack in the meter assembly lead between the meter assembly and the plastic band. The rubber boot on the meter assembly can be bent as shown. Place the slack of the left and right front turn signal light leads between the headlight assembly and front cowling assembly. 2 - 37 CABLE ROUTING Fasten the left and right front turn signal light leads to the headlight stay with a plastic locking tie. Pass the left and right front turn signal light leads in front of the headlight stay. Only the left side is shown in this illustration. Route the right front turn signal light lead in the same way. Pass the left and right front turn signal light leads between the headlight stay and front fork protector. SPEC 0 ~ 5 mm (0 ~ 0.20 in) for both left and right sides 2 - 38 CABLE ROUTING 1 Ignition coil lead 2 Main switch coupler 3 Immobilizer unit coupler 4 Air induction system lead 5 Horn lead 6 Horn 7 Ignition coil 8 Spark plug lead 9 Clutch cable 0 Oil delivery pipe 1 A Wire harness SPEC B Fast idle plunger outlet hose Fasten the fast idle plunger outlet hose and ignition coil leads with a hose holder. Install the hose holder with its fastener facing down. Fasten the wire harness, main switch lead, and immobilizer unit lead to the frame with a plastic band. A B-B B 4 3 1 2 B 5 B A A 6 7 8 9 0 9 A-A 2 - 39 CABLE ROUTING Fasten the main switch lead, immobilizer unit lead, and horn switch lead with a plastic locking tie. To fasten the leads, connect the couplers, and then turn the handlebar completely to the left. Fasten the main switch lead, immobilizer unit lead, and clutch cable with a plastic band under the engine oil filler cap. To fasten the leads and cable, connect the couplers, and then turn the handlebar completely to the left. SPEC Fasten the clutch cable to the horn bracket with a cable holder. Install the cable holder as high as possible. Fasten the clutch cable and oil delivery pipe 1 with a cable holder. Route the fast idle plunger outlet hose to the inside of the line shown in the illustration so that it is not pinched between the frame and right side panel. A B-B B 4 3 1 2 B 5 B A A 6 7 8 9 0 9 A-A 2 - 40 CABLE ROUTING 1 Rear brake light switch lead 2 Negative battery lead 3 Lean angle cut-off switch lead 4 Throttle position sensor lead 5 Coolant temperature sensor lead 6 Turn signal/hazard relay 7 Headlight relay 8 Radiator fan motor relay 9 Relay unit SPEC Fasten the wire harness, negative battery lead, and rear brake light switch lead to the frame with a plastic locking tie. Fasten the rear brake light switch lead to the frame with a plastic locking tie. Fasten the wire harness to the frame at the white tape with a plastic locking tie. Route the negative battery lead behind the lean angle cut-off switch bracket. Route the rear brake light switch lead between the air filter case and the frame. 1 2 3 4 5 9 8 7 6 2 - 41 CABLE ROUTING 1 Neutral switch connector 2 Crankshaft position sensor coupler 3 A.C. magneto coupler 4 Speed sensor lead 5 Intake air temperature sensor lead 6 ECU lead 7 Starter motor lead 8 Sidestand switch lead 9 Speed sensor 0 A.C. magneto lead A Oil tank breather hose B Oil delivery hose 2 C Radiator fan motor lead D Throttle cable E Headlight lead F Meter assembly lead G Left handlebar switch lead H Right handlebar switch lead I Front brake light switch lead J Clutch switch lead SPEC K Immobilizer unit lead L Clutch cable M Main switch lead N Air-filter-to-air-cut-off-valve hose O Wire harness FG E D M LK A-A A B C A B D G H I J B-B B C-C H E D F C IJ D 1 2 3 4 567 E C D N C B O A E-E D B A 8 E F F-F F 0 9 8 2 - 42 CABLE ROUTING Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, and clutch switch lead to the frame with a plastic locking tie. To fasten the leads, connect the couplers, and then turn the handlebar completely to the right. SPEC Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, clutch switch lead, radiator fan motor lead, and throttle cables with a plastic locking tie. To fasten the leads and cables, connect the couplers, and then turn the handlebar completely to the right. Route the oil tank breather hose on the outside of the throttle cables. FG E D M LK A-A A B C A B D G H I J B-B B C-C H E D F C IJ D 1 2 3 4 567 E C D N C B O A E-E D B A 8 E F F-F F 0 9 8 2 - 43 CABLE ROUTING Fasten the wire harness to the frame at the white tape with a plastic locking tie. Fasten the starter motor lead to the frame with a plastic locking tie. Fasten the sidestand switch lead to the frame with a plastic locking tie. Route the sidestand switch lead at the front end of the left side heel plate. SPEC Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed sensor lead, starter motor lead, and A.C. magneto lead with a plastic band. Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed sensor lead, and starter motor lead with a plastic band. Fasten the air-filter-to-air-cut-off-valve hose, oil tank breather hose, and oil delivery hose 2 with a plastic clamp. FG E D M LK A-A A B C A B D G H I J B-B B C-C H E D F C IJ D 1 2 3 4 567 E C D N C B O A E-E D B A 8 E F FF F 0 9 8 2 - 44 CABLE ROUTING Fasten the wire harness, air-filter-to-air-cut-offvalve hose, and oil delivery hose 2 with a plastic clamp. Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, and clutch switch lead with a plastic band. SPEC FG E D M LK A-A A B C A B D G H I J B-B B C-C H E D F C IJ D 1 2 3 4 567 E C D N C B O A E-E D B A 8 E F F-F F 0 9 8 2 - 45 CABLE ROUTING 1 Starter motor lead 2 Fuse box 1 lead 3 Fuse box 2 lead 4 Tail/brake light lead 5 Rear turn signal light lead 6 Seat lock cable 7 Positive battery lead 8 Starter relay lead 9 Rectifier/regulator lead SPEC Fasten the wire harness and starter motor lead to the frame with a plastic locking tie. 45 Fasten the wire harness to the frame with a plastic band. 4 12 3 5 6 7 8 9 2 - 46 CABLE ROUTING 1 Immobilizer unit coupler 2 Intake air temperature sensor 3 Fuel injector lead 4 Fuel pump lead 5 Fuel sender lead 6 Oil tank breather hose SPEC 0 ~ 10 mm (0 ~ 0. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 39 in) 30 ~ 40 mm (1.18 ~ 1.57 in) 5 ~ 15 mm (0.20 ~ 0. 59 in) Fasten the wire harness to the frame with a plastic locking tie. To the fuel tank 0 ~ 5 mm (0 ~ 0.20 in) For F, GB 1 1 6 A A 5 2 4 3 2 - 47 CABLE ROUTING 1 Battery 2 Negative battery lead 3 Tail/brake light coupler 4 Rear turn signal light connector 5 Seat lock cable 6 Anti-theft alarm coupler 7 Fuse box 2 8 Positive battery lead 9 Fuse box 1 0 Rear fender A Rear fender cover SPEC Fasten the tail/brake light lead with two plastic locking ties so that the coupler is positioned to the inside of where the relays (turn signal/hazard relay, headlight relay, radiator fan motor relay, and relay unit) branch off from the wire harness. To relays (turn signal/hazard relay, headlight relay, radiator fan motor relay, and relay unit) Fasten the rear turn signal light leads and tail/ brake light lead with a lead holder. 9 8 7 1 2 6 5 0 A A 3 4 A A-A 2 - 48 CABLE ROUTING Connect the couplers so that they are not pinched between the rear fender and rear fender cover. Fasten the wire harness to the frame with a plastic locking tie. 0 ~ 5 mm (0 ~ 0.20 in) 0 ~ 10 mm (0 ~ 0.39 in) The tail/brake light coupler and the rear turn signal light lead should not be lower than the line shown in the illustration. SPEC 9 8 7 1 2 6 5 0 A A 3 4 A A-A 2 - 49 CABLE ROUTING 1 Front brake hose 2 Front brake master cylinder 3 Front mud guard 4 Front brake caliper 5 Front fork boss SPEC To install the brake hose holders, align the edge of each holder with the upper edge of the recess in the brake hose. Route the front brake hose so that its alignment mark is facing toward the rear of the motorcycle. 30 ~ 50 Fasten the front brake hose with the brake hose holders. 2 - 50 CABLE ROUTING Route the front brake hose between the front fork and front mud guard and between the bosses on the front fork. When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown. When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the projection on the brake caliper. SPEC 2 - 51 CABLE ROUTING 1 Brake fluid reservoir 2 Brake fluid reservoir hose 3 Rear brake light switch 4 Rear brake master cylinder 5 Rear brake hose 6 Rear brake caliper SPEC When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the brake master cylinder as shown. Fasten the rear brake hose with the brake hose holder. When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown. 2 - 52 CHK ADJ 3 CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... ....... 3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ... ..... ..... .......... ..... 3-1 COWLING AND COVER ..... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... ...... 3-3 COVER.... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... ........ 3-3 COWLING .. ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... 3-4 FUEL TANK..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... ...... 3-5 REMOVING THE FUEL TANK .... .......... ..... ..... .......... .......... ..... ..... .......... ..3-6 REMOVING THE FUEL PUMP ........ ..... ..... .......... .......... ..... ..... .......... .......3-6 INSTALLING THE FUEL PUMP... ..... ..... .......... .......... ..... ..... .......... .......... .3-7 INSTALLING THE FUEL HOSE .... ..... .......... .......... ..... ..... .......... .......... ..... 3-7 AIR FILTER CASE ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... 3-8 REAR MUD GUARD AND REAR FENDER ..... .......... .......... ..... ..... .......... .3-8 AIR FILTER CASE ......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... ... 3-10 INSTALLING THE AIR FILTER CASE JOINT CLAMP ....... .......... ..... ..... 3-12 ENGINE .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .....3-13 ADJUSTING THE VALVE CLEARANCE ..... ..... ..... .......... .......... ..... ..... ... 3-13 ADJUSTING THE EXHAUST GAS VOLUME ....... .......... ..... ..... .......... ....3-16 ADJUSTING THE ENGINE IDLING SPEED ...... ..... ..... .......... .......... ..... ..3-17 ADJUSTING THE THROTTLE CABLE FREE PLAY ... .......... .......... ..... ..3-17 CHECKING THE SPARK PLUG ... .......... .......... ..... ..... .......... .......... ..... ... 3-19 CHECKING THE IGNITION TIMING.. .......... .......... ..... ..... .......... .......... ...3-20 MEASURING THE COMPRESSION PRESSURE.. ..... .......... .......... ..... ..3-21 CHECKING THE ENGINE OIL LEVEL... .......... .......... ..... ..... .......... .........3-23 CHANGING THE ENGINE OIL . ..... ..... .......... .......... ..... ..... .......... .......... ..3-24 ADJUSTING THE CLUTCH CABLE FREE PLAY... ..... .......... .......... ..... .. 3-27 CHECKING THE AIR FILTER ELEMENT ... .......... .......... ..... ..... .......... .... 3-28 CHECKING THE THROTTLE BODY JOINT...... ..... ..... .......... .......... ..... ..3-29 CHECKING THE FUEL HOSE ... .......... .......... ..... ..... .......... .......... ..... ..... .3-29 CHECKING THE BREATHER HOSE......... .......... ..... ..... .......... .......... ..... 3-30 CHECKING THE EXHAUST SYSTEM..... .......... .......... ..... ..... .......... .......3-30 CHECKING THE COOLANT LEVEL... ..... ..... .......... .......... ..... ..... .......... ..3-31 CHECKING THE COOLING SYSTEM ........ ..... ..... .......... .......... ..... ..... ....3-31 CHANGING THE COOLANT...... .......... ..... ..... .......... .......... ..... ..... .......... . 3-32 CHK ADJ CHASSIS ......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .......... .......... .... 3-36 ADJUSTING THE REAR BRAKE PEDAL . ..... .......... .......... ..... ..... .......... . 3-36 CHECKING THE BRAKE FLUID LEVEL......... ..... ..... .......... .......... ..... ..... 3-37 CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS .......... .......... ..... ..... .......... .......... ..... ..... .......... ...3-38 ADJUSTING THE REAR BRAKE LIGHT SWITCH ....... ..... ..... .......... ......3-38 CHECKING THE FRONT AND REAR BRAKE HOSES.... ..... ..... .......... .. 3-39 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........ ..... ..... .......... ....... 3-40 ADJUSTING THE SHIFT PEDAL... ..... ..... .......... .......... ..... ..... .......... ....... 3-41 ADJUSTING THE DRIVE CHAIN SLACK ... ..... ..... .......... .......... ..... ..... .... 3-42 LUBRICATING THE DRIVE CHAIN ...... .......... ..... ..... .......... .......... ..... ..... 3-44 CHECKING AND ADJUSTING THE STEERING HEAD .......... .......... ..... 3-44 CHECKING THE FRONT FORK ..... .......... .......... ..... ..... .......... .......... ..... . 3-46 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.... .......... .... 3-47 CHECKING THE TIRES...... ..... ..... .......... .......... ..... ..... .......... .......... ..... ...3-48 CHECKING AND TIGHTENING THE SPOKES.. .......... .......... ..... ..... ...... 3-51 CHECKING AND LUBRICATING THE CABLES .... .......... ..... ..... .......... .. 3-52 LUBRICATING THE LEVERS AND BRAKE PEDAL ........ ..... ..... .......... ..3-52 LUBRICATING THE SIDESTAND........ ..... ..... .......... .......... ..... ..... .......... . 3-52 ELECTRICAL SYSTEM......... ..... ..... .......... .......... ..... ..... .......... .......... ..... ..... .. 3-53 CHECKING AND CHARGING THE BATTERY........ .......... ..... ..... .......... . 3-53 CHECKING THE FUSES ......... ..... ..... .......... .......... ..... ..... .......... .......... ...3-58 REPLACING THE HEADLIGHT BULB.. ..... .......... .......... ..... ..... .......... .....3-60 ADJUSTING THE HEADLIGHT BEAM ..... ..... ..... .......... .......... ..... ..... ......3-61 SETTING THE DIGITAL CLOCK .... .......... ..... ..... .......... .......... ..... ..... ...... 3-62 INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION CHART EAS00036 CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. EAS00037 PERIODIC MAINTENANCE AND LUBRICATION CHART NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING ( 1,000 km) 1 10 20 30 40 ANNUAL CHECK No. 1* ITEM Fuel line (See page 3-29) Spark plug (See page 3-19) CHECK OR MAINTENANCE JOB Check fuel hoses for cracks or damage. Check condition. Clean and regap. Replace. Check valve clearance. Adjust. Replace. Check operation. Adjust. Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. Check for cracks or damage. Replace. Check runout, spoke tightness and for damage. Tighten spokes if necessary. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 2 Valves 3* (See page 3-13) 4 5 Air filter element (See page 3-28) Clutch (See page 3-27) Front brake 6 * (See page 3-37, 3-38) Rear brake 7 * (See page 3-36, 3-37, 3-38) Brake hoses 8* (See page 3-39) Wheels 9 * (See page 4-3, 4-14) Tires 10 * (See page 3-48) Wheel bearings (See page 4-3) Swingarm (See page 4-83) Drive chain (See page 3-42, 4-84) Whenever worn to the limit Whenever worn to the limit Every 4 years 11 * 12 * Check bearing for looseness or damage. Check operation and for excessive play. 13 Check chain slack. Every 500 km and after washing the motorcycle or Make sure that the rear wheel is properly aligned. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 riding in the rain Clean and lubricate. Check bearing play and steering for roughness. Lubricate with lithium-soap-based grease. Steering bearings 14 * (See page 3-44, 4-71) Every 20,000 km 3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART No. 15 * 16 17 * 18 * ITEM Chassis fasteners (See page 2-23) Sidestand (See page 3-53) Sidestand switch (See page 8-5) Front fork (See page 3-46) CHECK OR MAINTENANCE JOB Make sure that all nuts, bolts and screws are properly tightened. Check operation. Lubricate. Check operation. Check operation and for oil leakage. Check operation and shock absorber for oil leakage. 1 10 20 CHK ADJ 30 40 ANNUAL CHECK ODOMETER READING ( 1,000 km) Shock absorber 19 * assembly (See page 3-47) Rear suspension relay arm and con20 * necting arm pivot- Check operation. ing points (See page 4-78) Electronic fuel 21 * injection (See page 3-17) 22 Engine oil (See page 3-23, 3-24) Engine oil filter element (See page 3-24) Adjust engine idling speed. Change. Check oil level and vehicle for oil leakage. 23 Replace. Check coolant level and vehicle for coolant leakage. Change. Cooling system 24 * (See page 3-31, 3-32) Front and rear brake switches 25 * (See page 3-38, 8-5) 26 Moving parts and cables (See page 3-52) Every 3 years Check operation. Lubricate. Throttle grip hous- Check operation and free play. Adjust the throttle cable free play if necessary. 27 * ing and cable Lubricate the throttle grip housing and cable. (See page 3-17) Air induction sys28 * tem (See page 7-36) Mufflers and 29 * exhaust pipes (See page 3-30) Check the air cut-off valve, reed valve, and hose for damage. Replace the entire air induction system if necessary. Check the screw clamps for looseness. Lights, signals and Check operation. 30 * switches Adjust headlight beam. (See page 3-61) NOTE: Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. 3-2 COWLING AND COVER COWLING AND COVER COVER CHK ADJ 7 Nm (0.7 m kg, 5.1 ft Ib) 3 1 4 5 Order 1 2 3 4 5 T. R. 4 23 Nm (2.3 m kg, 17 ft Ib) T. R. 2 7 Nm (0.7 m kg, 5.1 ft Ib) T. R. Job/Part Removing the cover Seat Left side panel Right side panel Grab bar Rear cover Q'ty 1 1 1 2 1 Remarks Remove the parts in the order listed. For installation, reverse the removal procedure. 3-3 COWLING AND COVER CHK ADJ COWLING 5 3 4 2 1 8 Nm (0.8 m kg, 5. 8 ft Ib) T 7 Nm (0.7 m kg, 5.1 ft Ib) . R. T. R. Order 1 2 3 4 5 Job/Part Removing the cowling Seat/side panels (left and right) Fuel tank Front fender Front fork protector Meter assembly coupler Subwire harness coupler Front cowling assembly Q'ty Remarks Remove the parts in the order listed. Refer to "COWLING AND COVER". Refer to "FUEL TANK". 1 1 2 1 1 Disconnect. Disconnect. For installation, reverse the removal procedure. 3-4 FUEL TANK EAS00040 CHK ADJ FUEL TANK 9 10 Nm (1.0 m kg, 7.2 ft Ib) 4 3 5 8 10 T. R. 2 6 7 1 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the fuel tank Seat/side panels (left and right) Fuel Fuel tank left side cover Fuel tank right side cover Intake air guide Fuel tank plate Damper 1 Fuel pump coupler Fuel sender coupler Fuel hose Fuel tank Damper 2 Q'ty Remarks Remove the parts in the order listed. Refer to "COWLING AND COVER". Drain. 1 1 1 1 1 1 1 1 1 1 Disconnect. Disconnect. Refer to "REMOVING THE FUEL TANK" and "INSTALLING THE FUEL HOSE". For installation, reverse the removal procedure. 3-5 FUEL TANK CHK ADJ REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank filler tube with a pump. 2. Remove: fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it. NOTE: To remove the fuel hose from the fuel injection pipe, slide the cover a on the end of the hose in the direction of the arrow shown and then remove the hose. Before removing the hose, place a few rags in the area under where it will be removed. 3. Remove: fuel tank NOTE: Do not set the fuel tank down so that the installation surface of the fuel pump is directly under the tank. Be sure to lean the fuel tank in an upright position. a REMOVING THE FUEL PUMP 1. Remove: fuel pump CAUTION: Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender. 3-6 FUEL TANK CHK ADJ INSTALLING THE FUEL PUMP 1. Install: 4 Nm (0.4 m kg, 2.9 ft lb) fuel pump NOTE: Do not damage the installation surfaces of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Align the projection a on the fuel pump with the slot in the fuel pump bracket. Tighten the bolts to the specified torque in the proper tightening sequence as shown. Install the fuel pump in the direction shown in the illustration. T. INSTALLING THE FUEL HOSE 1. Install: fuel hose CAUTION: When installing the fuel hose, be sure to securely connect it. R. a NOTE: To install the fuel hose from the fuel injection pipe, slide the cover a on the end of the hose in the direction of the arrow shown. 3-7 AIR FILTER CASE AIR FILTER CASE REAR MUD GUARD AND REAR FENDER CHK ADJ 7 Nm (0.7 m kg, 5.1 ft Ib) T. R. 1 7 Nm (0.7 m kg, 5.1 ft Ib) T. 7 R. 2 2 7 Nm (0.7 m kg, 5.1 ft Ib) T. R. 3 4 5 8 6 7 Nm (0.7 m kg, 5.1 ft Ib) T. R. Order 1 2 Job/Part Removing the rear mud guard and rear fender Seat/side panels (left and right)/rear cover Fuel tank Muffler Battery cover Battery lead Q'ty Remarks Remove the parts in the order listed. Refer to "COWLING AND COVER". Refer to "FUEL TANK". Refer to "ENGINE" in chapter 5. 1 2 Disconnect. CAUTION: First, disconnect the negative battery lead, then the positive battery lead. 3 4 5 Battery Tali/brake light coupler Rear turn signal light connector 1 1 4 Disconnect. Disconnect. 3-8 AIR FILTER CASE CHK ADJ 7 Nm (0.7 m kg, 5.1 ft Ib) T. R. 1 7 Nm (0.7 m kg, 5.1 ft Ib) T. 7 R. 2 2 7 Nm (0.7 m kg, 5.1 ft Ib) T. R. 3 4 5 8 6 7 Nm (0. 7 m kg, 5.1 ft Ib) T. R. Order 6 7 8 Job/Part Fuse box 2 Rear mud guard Rear fender Q'ty 1 1 1 Remarks For installation, reverse the removal procedure. 3-9 AIR FILTER CASE EAS00043 CHK ADJ AIR FILTER CASE 10 Nm (1. You're reading an excerpt. Click here to read official YAMAHA XT660X user guide http://yourpdfguides.com/dref/569676 Powered by TCPDF (www.tcpdf.org)